US7128620B2 - Element for connecting a flexible conductor and method for connecting a flexible conductor to a connection terminal - Google Patents

Element for connecting a flexible conductor and method for connecting a flexible conductor to a connection terminal Download PDF

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Publication number
US7128620B2
US7128620B2 US10/510,601 US51060104A US7128620B2 US 7128620 B2 US7128620 B2 US 7128620B2 US 51060104 A US51060104 A US 51060104A US 7128620 B2 US7128620 B2 US 7128620B2
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Prior art keywords
flexible conductor
connection terminal
junction
faces
face
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Expired - Lifetime
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US10/510,601
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US20060121799A1 (en
Inventor
Massimo Maura
Federico Gamba
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ABB SpA
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ABB Service SRL
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Assigned to ABB SERVICE S.R.L. reassignment ABB SERVICE S.R.L. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GAMBA, FEDERICO, MAURA, MASSIMO
Publication of US20060121799A1 publication Critical patent/US20060121799A1/en
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Assigned to ABB S.P.A. reassignment ABB S.P.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ABB SERVICE S.R.L.
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H1/00—Contacts
    • H01H1/58—Electric connections to or between contacts; Terminals
    • H01H1/5822—Flexible connections between movable contact and terminal
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H71/00—Details of the protective switches or relays covered by groups H01H73/00 - H01H83/00
    • H01H71/08—Terminals; Connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/02—Soldered or welded connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0207—Ultrasonic-, H.F.-, cold- or impact welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
    • H01R43/0221—Laser welding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H11/00—Apparatus or processes specially adapted for the manufacture of electric switches
    • H01H2011/0087—Welding switch parts by use of a laser beam

Definitions

  • the present invention relates to an element for connecting flexible conductors, particularly for low-voltage circuit breakers and contactors, and to a method for connecting a flexible conductor, particularly one or more braids, to a connection terminal, particularly to a connection terminal of a moving contact of a low-voltage circuit breaker or contactor, by laser welding.
  • Electric circuit breakers and contactors are normally provided with a flexible conductor, which functionally connects a moving contact and a stationary contact.
  • the methods of the background art for providing the junctions of the flexible conductor with the moving contact and with the stationary contact are normally based on braze-welding processes.
  • connection terminal that surrounds the welding region, both on the moving contact and on the stationary terminal, is also subjected to the annealing action caused by the heat, with consequent deterioration of the mechanical properties of these components.
  • Ultrasound welding for example, does not have the annealing drawbacks cited above, but is not practical to use in view of its known power limits.
  • the aim of the present invention is to provide a junction between a flexible conductor and a connection terminal that has high mechanical stability and high electrical conductivity and can be manufactured efficiently.
  • an object of the present invention is to provide a method for connecting a flexible conductor to a connection terminal that does not cause degradation of the mechanical properties of the conductor and/or of the connection terminal.
  • Another object of the present invention is to provide a method for connecting a flexible conductor to a connection terminal that ensures high electrical conductivity.
  • Another object of the present invention is to provide a junction between a copper braid and a connection terminal in a low-voltage circuit breaker or contactor.
  • Another object of the present invention is to provide a method for connecting a copper braid to a connection terminal in a low-voltage circuit breaker or contactor.
  • Another object of the present invention is to provide a method for connecting a flexible conductor to a connection terminal, and a junction between a flexible conductor and a connection terminal, that is simple to apply industrially, at modest costs and in an economically competitive manner.
  • Another aspect of the present invention is a method for providing a junction between a flexible conductor and a connection terminal, characterized in that it comprises the steps that consist in:
  • FIG. 1 is a schematic perspective view of a connection terminal and of the flexible conductors according to the present invention.
  • FIG. 2 is a schematic perspective view of a junction between flexible conductors and a connection terminal according to the invention, and of a method according to the invention for providing said junction.
  • connection terminal 1 which is shaped substantially like a parallelepiped, with an upper face 11 and a lower face 12 , two lateral faces 13 and 14 and an end face 15 .
  • the connection terminal has, on the end face 15 , one or more substantially parallelepipedal slots 150 , which run through the entire thickness of the connection terminal.
  • the end face 15 has, in the example, a square-wave profile.
  • a second element that constitutes the junction is a flexible conductor 2 , which has an end part 21 that is shaped so as to mate substantially with the inner walls of the slots 150 .
  • the junction according to the invention is constituted by the end part 21 of the conductor 2 that is inserted in the slots 150 .
  • the flexible conductor 2 in this case protrudes substantially at right angles from the lower face 12 of the connection terminal 1 .
  • At least one laser welding bead 3 runs along the connection terminal 1 at the slots 150 along the end face 15 and/or along the face that lies opposite the one from which the flexible conductor protrudes. In the case of FIG. 2 there are laser welding beads 3 both along the end face 15 and along the upper face 11 .
  • welding bead designates the molten material generated by the scanning of laser means along preset lines.
  • the flexible conductor 2 is constituted by one or more copper braids.
  • the shaped end part 21 of the flexible conductor 2 can be obtained conveniently by compressing said braid.
  • the junction is relatively large, it is preferable to provide multiple laser welding beads 3 ; in this case, it is convenient to have said beads run both along the end face and, for example and with reference to FIG. 2 , along the face 11 , which in this case is the face that lies opposite the face 12 from which the flexible conductors 2 protrude.
  • junctions according to the invention are applied conveniently for example in low-voltage circuit breakers and contactors.
  • Said circuit breakers and contactors in their most schematic form, comprise at least one moving contact, a flexible conductor, and a connection terminal.
  • junctions between the moving contact and the flexible conductor, and between the flexible conductor and the connection terminal can be constituted conveniently by a junction according to the present invention.
  • Said circuit breakers and contactors constitute a further aspect of the present invention.
  • connection terminal 1 shaped substantially like a parallelepiped is prepared which has an upper face 11 , a lower face 12 , two side faces 13 and 14 and an end face 15 ; one or more slots 150 shaped substantially like a parallelepiped are provided on the end face 15 and run through the entire thickness of said connection terminal.
  • a flexible conductor 2 is provided which has an end part 21 that is shaped so as to substantially mate with the inner walls of said slots.
  • the shaped end part 21 is inserted and cold-coined in the slots 150 , so that the flexible conductor 2 protrudes substantially at right angles from one of said upper, lower or end faces of the connection terminal, for example from the lower face 12 .
  • the end face 15 and/or the lower face 12 are subjected to the welding action of laser means 40 (shown schematically) to provide a weld between the connection terminal and the flexible conductor.
  • the flexible conductor is preferably constituted by one or more copper braids, and the shaped end part is obtained by compressing said braid.
  • the welding action is preferably obtained by virtue of the scanning of laser means on the faces 15 and/or 11 or 12 , along a direction that is substantially perpendicular to the lateral faces 13 and 14 of the connection terminal.
  • the laser means perform multiple scans both on the end face 15 and on the face 11 or 12 , along directions that are substantially perpendicular to the lateral faces of the connection terminal.
  • said scanning can be performed by means of a relative movement of the laser means with respect to the components to be welded during the welding operation.
  • Said relative movement in practice can be provided by keeping motionless the components to be welded and moving the laser means, or by keeping motionless the laser means and moving the components to be welded, or by moving both.
  • the scanning speed, the angle of incidence and all the other physical parameters of the laser beam described in greater detail hereinafter can be chosen and modulated according to the characteristics of the elements to be welded, such as for example their chemical nature or their thickness, but can also be controlled and changed appropriately during the welding operations in order to compensate for the heating of the affected regions and in general in order to optimize the results.
  • the operating characteristics of the laser such as for example its frequency, power and angle of incidence, scanning speed and angle of incidence, can be chosen and modulated as a function of the characteristics of the elements to be welded and of the results to be obtained.
  • junctions that are excellent in terms of mechanical and electrical properties.
  • problems of copper annealing typical of braze welding processes are avoided.
  • the extremely high electrical conductivity given by cold-coining of the flexible conductors on the connection terminals is safeguarded even after the welding process according to the invention, thus avoiding the deterioration in conductivity that is instead typical of junctions subsequently subjected to the braze welding process.
  • Laser welding is left the task of stabilizing the system mechanically and of preventing the thermal expansions of the materials in operating conditions from compromising the electrical conductivity characteristics.
  • laser means allows to avoid applications of heat that would be critical and harmful for the mechanical characteristics of the individual components.
  • the method according to the invention is furthermore suitable for being inserted in automated production cycles, allowing for example to obtain circuit breakers, contactors and components of circuit breakers and contactors efficiently and relatively cheaply.
  • the materials used, as well as the contingent shapes and dimensions may be any according to the requirements and the state of the art.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Optics & Photonics (AREA)
  • Electromagnetism (AREA)
  • Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
  • Multi-Conductor Connections (AREA)
  • Processing Of Terminals (AREA)
  • Ladders (AREA)
  • Breakers (AREA)
US10/510,601 2002-04-12 2003-04-11 Element for connecting a flexible conductor and method for connecting a flexible conductor to a connection terminal Expired - Lifetime US7128620B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
IT2002MI000789A ITMI20020789A1 (it) 2002-04-12 2002-04-12 Elemento di connessione di un conduttore flessibile e metodo per connettere un conduttore flessibile ad un terminale di collegamento
ITMI2002A000789 2002-04-12
PCT/EP2003/003877 WO2003088288A2 (en) 2002-04-12 2003-04-11 Junction between a flexible conductor and a connection terminal and method herefor

Publications (2)

Publication Number Publication Date
US20060121799A1 US20060121799A1 (en) 2006-06-08
US7128620B2 true US7128620B2 (en) 2006-10-31

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
US10/510,601 Expired - Lifetime US7128620B2 (en) 2002-04-12 2003-04-11 Element for connecting a flexible conductor and method for connecting a flexible conductor to a connection terminal

Country Status (11)

Country Link
US (1) US7128620B2 (ru)
EP (1) EP1495518B2 (ru)
JP (1) JP2005522841A (ru)
CN (1) CN1647330B (ru)
AT (1) ATE345588T1 (ru)
AU (1) AU2003227619A1 (ru)
DE (1) DE60309687T3 (ru)
ES (1) ES2275093T5 (ru)
IT (1) ITMI20020789A1 (ru)
RU (1) RU2304331C2 (ru)
WO (1) WO2003088288A2 (ru)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110174785A1 (en) * 2010-01-15 2011-07-21 Tetsuro Ishida Laser Welding Structure
WO2013023830A1 (en) 2011-07-01 2013-02-21 Fci Automotive Holding Method for welding a cable to a terminal and the terminal obtained therefrom
US20170104287A1 (en) * 2014-07-01 2017-04-13 Te Connectivity Germany Gmbh Electrical Contact Unit and Electrical Welded Joint as Well as Method for Producing a Contact Unit and for Configuring a Welded Joint
US10879139B2 (en) * 2018-09-06 2020-12-29 Mitsubishi Electric Corporation Semiconductor device, power converter, and method of manufacturing semiconductor device
US20220029370A1 (en) * 2020-07-22 2022-01-27 Yazaki Corporation Electric wire manufacturing method and electric wire manufacturing apparatus
US20220085589A1 (en) * 2020-09-16 2022-03-17 Yazaki Corporation Waterproof construction of three-phase line part and three-phase line connecting device
WO2024061999A1 (de) * 2022-09-21 2024-03-28 Auto-Kabel Management Gmbh Verfahren, verbindungsanordnung und verwendung einer verbindungsanordnung für zumindest zwei litzenleitungen

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102714095B (zh) * 2009-12-24 2016-03-30 三菱电机株式会社 电子元器件装置
FR2987220B1 (fr) * 2012-02-17 2016-10-28 Tresse Metallique J Forissier Dispositif de conduction thermique et son procede de fabrication
KR101323606B1 (ko) 2012-09-14 2013-11-01 엘에스산전 주식회사 배선용 회로차단기의 가동접점 대
CN103065821A (zh) * 2012-12-28 2013-04-24 常熟开关制造有限公司(原常熟开关厂） 自动转换开关的触头机构
WO2015107220A1 (en) * 2014-01-20 2015-07-23 Zettler Electronics Gmbh Contact arrangement for high power relay
CN104091728A (zh) * 2014-07-16 2014-10-08 无锡市凯旋电机有限公司 框架断路器接线端子
US9570826B2 (en) * 2014-12-08 2017-02-14 Eaton Corporation Connection apparatus usable in vacuum interrupter
TR2022012342A2 (tr) * 2022-08-04 2022-08-22 Eae Elekt Asan End Insaat San Ve Tica S Enerji̇ dağitim si̇stemleri̇nde esnek i̇letken i̇le soli̇d i̇letkeni̇ bi̇rleşti̇rme terti̇bati

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4583065A (en) * 1983-12-13 1986-04-15 Merlin Gerin Electric connection of braids on a circuit breaker terminal
US4774394A (en) 1987-09-02 1988-09-27 E. I. Du Pont De Nemours And Company Laser welding method
US5163221A (en) * 1990-07-19 1992-11-17 Merlin Gerin Method of welding a flexible conductor to a contact finger
US5300755A (en) * 1991-08-12 1994-04-05 Yazaki Corporation Structure for welding electrical connecting portions to each other using laser light beam
EP0887884A2 (en) 1997-05-28 1998-12-30 Harness System Technologies Research, Ltd. Bus bar structure
US6121560A (en) * 1996-06-21 2000-09-19 Siemens Aktiengesellschaft Switching contact system for a low voltage power switch with flexible conductors
US20010011418A1 (en) 2000-01-22 2001-08-09 Robert Schwemmer Method for producing an electrically conductive connection by laser radiation

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JPS57132306A (en) † 1981-02-10 1982-08-16 Toshiba Corp Electromagnetic coil and manufacture therefor
US5093988A (en) † 1991-01-24 1992-03-10 Kohler Co. Method for attaching a flexible connector
US5268555A (en) † 1992-08-31 1993-12-07 General Electric Company Apparatus and method for laser joining 218 bimetal to molded case circuit breaker (MCCB) hooks and terminals
DE4416104C2 (de) † 1994-04-19 2000-07-13 Siemens Ag Schaltkontaktanordnung eines elektrischen Leistungsschalters
DE19627324A1 (de) † 1996-06-26 1998-01-02 Siemens Ag Verfahren zur Verbindung eines starren Leiterstückes mit biegsamen Leitern

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4583065A (en) * 1983-12-13 1986-04-15 Merlin Gerin Electric connection of braids on a circuit breaker terminal
US4774394A (en) 1987-09-02 1988-09-27 E. I. Du Pont De Nemours And Company Laser welding method
US5163221A (en) * 1990-07-19 1992-11-17 Merlin Gerin Method of welding a flexible conductor to a contact finger
US5300755A (en) * 1991-08-12 1994-04-05 Yazaki Corporation Structure for welding electrical connecting portions to each other using laser light beam
US6121560A (en) * 1996-06-21 2000-09-19 Siemens Aktiengesellschaft Switching contact system for a low voltage power switch with flexible conductors
EP0887884A2 (en) 1997-05-28 1998-12-30 Harness System Technologies Research, Ltd. Bus bar structure
US6761598B2 (en) * 1997-05-28 2004-07-13 Autonetworks Technologies, Ltd. Bus bar structure
US20010011418A1 (en) 2000-01-22 2001-08-09 Robert Schwemmer Method for producing an electrically conductive connection by laser radiation
US6531676B2 (en) * 2000-01-22 2003-03-11 Robert Bosch Gmbh Method for producing an electrically conductive connection by laser radiation

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110174785A1 (en) * 2010-01-15 2011-07-21 Tetsuro Ishida Laser Welding Structure
US8430699B2 (en) * 2010-01-15 2013-04-30 Tyco Electronics Japan G.K. Laser welding structure
WO2013023830A1 (en) 2011-07-01 2013-02-21 Fci Automotive Holding Method for welding a cable to a terminal and the terminal obtained therefrom
US9728927B2 (en) 2011-07-01 2017-08-08 Delphi International Operations Luxembourge, Sarl Method for welding a cable to a terminal
US20170104287A1 (en) * 2014-07-01 2017-04-13 Te Connectivity Germany Gmbh Electrical Contact Unit and Electrical Welded Joint as Well as Method for Producing a Contact Unit and for Configuring a Welded Joint
US10218101B2 (en) * 2014-07-01 2019-02-26 Te Connectivity Germany Gmbh Electrical contact unit and electrical welded joint as well as method for producing a contact unit and for configuring a welded joint
US10879139B2 (en) * 2018-09-06 2020-12-29 Mitsubishi Electric Corporation Semiconductor device, power converter, and method of manufacturing semiconductor device
US20220029370A1 (en) * 2020-07-22 2022-01-27 Yazaki Corporation Electric wire manufacturing method and electric wire manufacturing apparatus
US20220085589A1 (en) * 2020-09-16 2022-03-17 Yazaki Corporation Waterproof construction of three-phase line part and three-phase line connecting device
US12088078B2 (en) * 2020-09-16 2024-09-10 Yazaki Corporation Waterproof construction of three-phase line part and three-phase line connecting device
WO2024061999A1 (de) * 2022-09-21 2024-03-28 Auto-Kabel Management Gmbh Verfahren, verbindungsanordnung und verwendung einer verbindungsanordnung für zumindest zwei litzenleitungen

Also Published As

Publication number Publication date
CN1647330B (zh) 2010-12-08
AU2003227619A1 (en) 2003-10-27
RU2304331C2 (ru) 2007-08-10
ES2275093T5 (es) 2011-02-22
DE60309687D1 (de) 2006-12-28
DE60309687T2 (de) 2007-09-13
EP1495518B2 (en) 2010-09-22
EP1495518B1 (en) 2006-11-15
DE60309687T3 (de) 2011-03-31
AU2003227619A8 (en) 2003-10-27
WO2003088288A8 (en) 2004-11-11
ITMI20020789A1 (it) 2003-10-13
WO2003088288A2 (en) 2003-10-23
JP2005522841A (ja) 2005-07-28
ES2275093T3 (es) 2007-06-01
ITMI20020789A0 (it) 2002-04-12
EP1495518A2 (en) 2005-01-12
WO2003088288A3 (en) 2004-02-26
CN1647330A (zh) 2005-07-27
ATE345588T1 (de) 2006-12-15
US20060121799A1 (en) 2006-06-08
RU2004133059A (ru) 2005-09-10

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